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By Yue Tian, Shengqian Wang, Lifeng Zhang

This paper is to discuss the removal of non-metallic inclusions from molten steel using a high frequency magnetic field. In experiments, a certain amount of aluminum was added to the molten steel in a crucible to generate aluminum inclusions. A layer of aluminum clusters were observed close to the wall of the crucible after the electromagnetic (EM) field was imposed. Three dimensional EM field and fluid flow simulation were performed and showed that over 91% inclusions transported to the skin depth (2.31 mm) of the molten steel. The calculation of inclusion removal agreed well with the experimental observation. The separation mechanisms of inclusions from the molten steel by the high frequency EM field were discussed.

Jan 1, 2014

By Milan Lj. Stamatovic

The hydrometallurgical recovery of zinc from recycled blast furnace dust from a steel plant (Smederevo Metallurgical Company, Yugoslavia) was investigated. The dust contained 22% Fe, 17% Zn and 0.2% Pb. X-Ray diffractometry showed that the main components were hematite and magnetite, in combination with zinc oxide. Individual particles were generally spherical and ranged in size from 10 to 150 microns; 63% were less than 33 microns in diameter. An effective hydrometallurgical approach proved to be by caustic leaching and electrowinning. Recovery of zinc in the form of zinc powder was over 90%; this material can be used for the cementation of impurities in the conventional hydrometallurgical process for zinc production.

Jan 1, 1994

By Lei Zhang, Shining Chen, Lina Wang, Pu Liu, Benquan Fu, Jiannyang Hwang

A PFS(polymeric ferric sulfate) coagulation-photocatalytic oxidation technology was used for advanced treatment of coking wastewater from secondary biological treatment. Effects of some key factors on TOC removal rate were investigated, and the results were compared with those of the common photocatalytic oxidation technology under the operating parameters of the photocatalytic oxidation defined. Single factor experimental results showed that TOC removal rate could reach 81%, when optimal operating conditions were as follows: TiO2 loading: 4.0g/L, irradiation time: 4h, initial pH is 5.1and PFS dosage:700mg/L. PFS coagulation and photocatalytic oxidation have synergistic effect, which is meaningful for highly efficient treatment of coking wastewater

Jan 1, 2015

By J. C. DeSantis

Thin, highly reflective rhodium films with metal compositions greater than 98% (elemental -weight percentage) have been deposited by chemical vapor deposition using Rh(allyl)3 (ally1 = q3-C3H5) in the presence of a hydrogen plasma. Uniform, crystalline films that adhere well to several types of substrates result from depositions at temperatures as low as 150°C. Depositions using H2 (no plasma), or an argon plasma yields material that is amorphous, contains a significant amount (>14%) of residual carbon, and has a dramatically slower growth rate. The composition of these materials does not vary significantly from that of the materials obtained from the in vacuo thermal deposition with Rh(allyl)3.

Jan 1, 1992

By Luis M. González, Guzmánm Guillermo D., Davis Juan C.

"The Teniente converter (CT) of the Ventanas Smelter and Refinery of Codelco-Chile has two tuyeres for dry concentrate injection directly into the melt.The diluted phase injection system can feed 15 to 20 kg of concentrate for 1 kg of air, which creates a very abrasive solid/gas phase. The tuyeres commonly used lasted for about 3.5 days due to the accelerated decay of the shell, and 1.5 hours were necessary for the replacement of new ones in the reactor.Tests were carried out with common shell tuyeres with a tungsten based welding cover, and a life span of 28 days was reached, increasing the Teniente converter operational continuity between 1.5 to 2 %."

Jan 1, 2009

By Seiji Yokoyama

As a series of fundamental study on the gas evaporation method, a levitation-melted aluminum was evaporated in the gas mixture of argon and ammonia to synthesize ultrafine particles of aluminum nitride. When the ammonia partial pressure were more than 2kPa, the formation ratio of aluminum nitride was about 95%. The particles of aluminum nitride were mainly hexagonal. The mean size of the particles of aluminum nitride was about 57 nm, and it was constant without depending on the temperature of the levitated aluminum and the partial pressure pf ammonia. The aluminum nitride was formed by the reaction between ammonia and condensed liquid aluminum particle whose size was relatively small.

Jan 1, 2006

By Sylvain Gouttebroze, Mohammed M'Hamdi

In a previous work, a small scale Bridgman furnace has been used to study silicon bi-grain crystallization at different cooling rate. This work expands the analysis by studying the mechanical interaction between the crucible and ingot during the solidification and cooling. The thermal model is based on a 2D-axisymetric heat-transfer model. The flux histories are then transferred to the ingot-crucible 3D-model. Anisotropic Elastic and Crystal Plasticity model are used to model the silicon deformation. Four different assumptions are applied to model the mechanical contact crucible-ingot and three grain misorientations are considered. The results show the strong impact of the alumina crucible contraction on the stresses and deformations in the silicon ingot.

Jan 1, 2015

By Huang Chao

The thermodynamics analysis on reducing-matting smelting of sulfide ore of lead, antimony and bismuth which use ferric oxide as sulfur fixed agent is first analyzed. Due to the analysis of reaction mechanism, ferric oxide is first reduced to ferrous oxide, then ferrous oxide produce reducing-matting reaction with sulfide ore and reducing agent as reaction equation: MeS+FeO+CO=Me+FeS+CO2. The reaction thermodynamic calculation shows that the reducing-matting reactions of lead sulfide, antimony sulfide, Jamesonite, and bismuth sulfide are feasible, but is infeasible for zinc sulfide. These conclusion provide a feasible method for solve the pollution which produced in the smelting of sulfide ore of lead, antimony and bismuth.

Jan 1, 2006

By Vânia L. L. Andrade

Igarapé Bahia Mine is located in Carajás area, northern Brazil. Currently Companhia Vale do Rio Doce operates there a CIP / heap leaching plant treating an oxide gold ore containing about 4 g Au /t and 0,2% Cu, which produces 11 t of gold per year. Recent geological survey has identified a signifcant copper-gold reserve underneath the oxide gold ore. The processing aspects of this copper-gold sulphide ore are described in this paper. It includes ore characterization studies, grinding and flotation tests, orebody variability assessment, flowsheet selection and preliminary economical evaluation Emphasis is given to studies aimed at depressing fluorine bearing minerals to achieve a clean and marketable flotation concentrate.

Jan 1, 1999

By Shuichiro Okada

Various efforts to reduce energy consumption and smelting cost are made at Tamano Smelter. Production of anode copper has been increased by about 30 % and energy requirement has been decreased about 50 % respectively. Challenges toward more higher goal are being continued. Details about the following are described in this paper. 1 Waste heat recovery Steam recovery at up-take of FSFE Heat recovery from waste gas of anode furnaces 2 Application of tonnage oxygen 3 Application of pulverized carbonaceous fuels to the flash smelting furnace with furnace electrodes ( FSFE ) 4 Application of computer control system to copper smelting 5 Improvement of the fugitive gas collecting system 6 Improvement of the mechanical tuyere puncher for the converter furnace

Jan 1, 1983

By S. S. Ibrahim

The left behind material after the combusion of fossel fuel in some power stations in Cairo; weighing tens of tons every years, was investigated. The material called "Fly Ashes" containing 7.5% Ni, 10.0% V and 9.50% Cr; could be considered as a promising source of such valiable elements. As well as the small grain size (050 70 "m) of the material, and besides the complexity of their formation history, hydrometallurgical methods appeared to be the effective technique to deal with. Yet, preconcentration is possible by means of magnetic and gravity separation methods. The end product is assaying 16.60% Ni and 20.2S!; V with weight recovery of about 60.15%.

Jan 1, 1995

By Onwukamike, Onyedika G. O, Ogwuegbu M. O. C., K., Onyenehide C

A detailed mineralogical and elemental characterization of a lead (Pb) ore deposit from Ishiagu, Ebonyi State, Nigeria was carried out with XRD, SEM-EDX, and ICP-OES based mappingtechniques. The results show that the most dominant and valuable metal is lead (Pb = 95.02%, mass fraction). The main mineral is galena. Ilmenite and sphalerite occur as minors, which account for 2.71% and 0.80% respectively. Elements like Al, Ca, Mg, Ti, Na, Mn, Si and Sn occurred in trace amounts and are disseminated in the entire ore body.The surface and interrelations of the crystals were examined with x-ray mapping and the result shows the pattern of dissemination of the minerals within the ore body.

Jan 1, 2015

By Jin Liu

The mechanism and rate of carbon reduction of each of the phases that are formed in the flash flame, i.e. sulfide (matte) and oxysulfide, was investigated. Graphite-slag reduction was conducted for comparison purposes. The objective of these tests was to measure the rate of solid graphite reduction of respectively matte, oxysulfide, slag, and matte+slag mixture at different temperatures. More in particular, these tests were expected to permit understanding and explaining the reduction mechanism of each material by comparing the respective reaction rates, product reaction gas compositions and CO/CO2 ratios, reduced material assays, activation energies, and other relevant parameters. Direct visual inspection of the test crucibles would provide additional information.

Jan 1, 2006

By J. Van Boven

The Hoboken plant has continued the program, started in 1973, for monitoring the impact of processes on the environment. Progressive improve¬ments including new installations and equipment have been commissioned resulting in reduced emissions of lead in air. The Hoboken Smelter now fully complies with regulation and observes a yearly mean value of less than 2 micrograms Pb per cubic meter of air in the vicinity of the plant. In addition a new central water-treatment installation permits the discharge of waste water to the River Schelde in accordance with present day regulations. Mention is made of methods used to measure the emissions and immissions at the plant. Results of modifications and new installations recently commissioned are discussed.

Jan 1, 1983

By Per Anders Eidem, Merete Tangstad, Jens Davidsen

"During excavations of submerged arc furnaces producing silicomanganese, silicon carbide (SiC) has been found. Contributing to the size of the inactive area of the furnace, the active area of the furnace where reactions occur will decrease, thus reducing the potential for pre-reduction in the furnace.This work studied the formation of SiC from the liquid-solid reaction between slag, metal, and metallurgical coke. Slags and metals with different levels of silica (S1O2) and silicon (Si) have been studied. The slag and metal has been heated together with coke, and the samples investigated by microprobe. The results show that SiC was formed on the coke particle through reactions with both slag and metal. For the metal, the carbon most likely diffused through the SiC to react with Si in the alloy. SiC formation with slag is likely to go through the reduction of Si02 to Si.IntroductionToday, Silicomanganese (SiMn) is produced in submerged arc furnaces (SAF) by reduction of S1O2 and manganese oxides, mainly with metallurgical cokes. Typically, the tapped metal has a silicon content of 17 - 20 wt.%. To achieve higher levels of Si, the metal can be refined by adding off-grade silicon metal, yielding low carbon SiMn. [1]. What is believed to be SiC that has been found during dig-outs of SiMn furnaces producing high silicon alloy. It is possible that excess amounts of SiC in the furnace cause operational problems, since SiC will occupy furnace volume. As SiC accumulates, the active volume of the furnace will decrease, increasing the flow of material and gas in the active areas of the furnace. Formation of SiC is inevitable, so it is desired to keep the formation as low as possible. To be able to control the formation of SiC, one has to understand the basic mechanisms."

Jan 1, 2012

By P. Tapp, T. Evans, N. A. Molloy, J. Lucas

"Consideration of the protoype tuyere geometry for injection of inert gas through the bottom in a basic oxygen steel furnace and a requirement to specify an optimal flow for bottom wear and metal penetration led to experimental investigations[l,2] to apply the results of previous workers to this specific case, Flow velocity profile development within the tuyere was proposed as significant and the experimental scheme was designed to test this. It is proposed that the design criterion for the conditions of optimal flow of the prototype geometry be based on the non-dimensional mass velocity.INTRODUCTIONSharma[3] tested small diameter tuyeres in a laboratory hot model using molten iron to define a flow criterion for prevention of penetration of the bath liquid into the tuyere. Using argon, nitrogen and helium through a range of tuyeres (1 to 3 mm ill ) he proposed the jet Froude number C Fr' ) with the critical value being 2400 - 2500 or higher. Sonic or supersonic velocity was not a sufficient criterion. The tuyere design was a parallel tubular duct of moderate aspect ratio CAR) i.e. the ratio of length to diameter ranging from about 22 to 36 in the experimental furnace.Farmer et al[4] stated their their aim ""to develop a unifying explanation and procedure for the proper design of tuyeres"" but disagreed with Sharma's jet Froude number criterion. Recalculating Sharma's data they proposed instead a fully expanded Mach number of 1.75 with an initial expansion angle of ten degrees as the lower bounds of flow to meet the design requirement. They experimented with tuyeres in a water model using tubular, annular and convergent-divergent nozzles. The aspect ratio of the parallel duct tuyeres was from 533 to 762 using diameters of 1.4, 1.7 and 2.0 mm C the diameters being of tubes to be used full scale). Subsequently these results were applied to a prototype tuyere using a diameter of 1.7 mm with beneficial results in practice. This tuyere had an aspect ratio of 1067."

Jan 1, 1996

By E. Kuzeci, R. Kammel

"Lately various voltametric methods have gained increased attention as an analytic tool in hydrometallurgy. Voltammograms with mercury drop electrodes or glassy carbon electrodes provide information about the electrocrystallization of cathodic deposits and allow calculation of kinetic data by means of characteristic parameters like the peak potential and peak current and their variation with the voltage scanning rate.Cyclic voltammograms are also suitable for identification of reaction sequences. Voltammograms with carbon paste electroactive electrodes containing metal sulphide additions reveal information about the dissolution behavior. The stripping voltammetry can be applied to analyze metal ions and organic additives (e. g., thiourea) in extreme low concentration. Typical application of the various methods studied with microcomputer controlled measurement system are explained by examples selected from copper hydrometallurgy.IntroductionThe use of electroanalytical methods in metallurgical process control can be dated back to the starting period of industrial copper refining, when the deposition of the metal ions was followed electro-gravimetrically by weighing the electrode with deposits (1). The principles of metal deposition and dissolution have not changed but the methods to follow these phenomena were subjected to noticeable developments and especially the introduction of polarographic investigations by Heyrowsky (2) has greatly contributed to the progress in electro-analysis. A review about the fundamental work on the electrochemical kinetics in earlier time is compiled in a monograph of Vetter (2). With the steady improvements in the instrumental techniques, it is nowadays possible to apply several current and potential modulations for measurements with improved selectivity and sensibility. There is however, still a lack in theoretical interpretation of the data obtained. More theoretical information are already available for linear voltametric methods for systems where reduced as well as oxidized species are dissolved in the electrolyte (4, 5). Some recent investigations have also shown the reliability of these techniques to study electro-crystallization (6, 7). Main fields of the application in the hydro - and electro-metallurgy are:"

Jan 1, 1989

By Kampe. S. L., Baker. Andrew H., Tony Zahrah

"Experimental heats of reaction for the formation of several Al3Ti + TiB2 intermetallic composite formulations have been determined utilizing bomb calorimetry. To overcome the kinetic constraints and achieve ignition in these formulations, a boron (B)/potassium nitrate (KNO3) initiation aid was incorporated within the blended reactant compact. The heat contribution from the initiation aid was regressed to provide estimates of the heat of reaction of the nominal formulations. Powder x-ray diffraction was utilized to identify the products of the reaction and discern any differences between the predicted equilibrium products of the formulation and the actual products.IntroductionReaction synthesis is a technique for the creation of ceramics, intermetallics, and in-situ composite materials [1]. Reaction synthesis is defined by its self, propagating mechanism, where the energy liberated from a localized reaction within a green powder compact is enough to carry the bulk reaction to completion. Achieving a self, propagating state can be achieved in variations of two primary methods of initiation: uniform volumetric heating and directional propagation [2].Uniform volumetric heating involves subjecting a green compact of the unreacted formulation to uniform heating in a furnace to encourage diffusion to initiate the reaction (Figure 1a) throughout the bulk material. Directional propagation utilizes a point heat source at one section of a green compact of unreacted formulation (Figure 1b). The localized exothermic reaction at one point in the compact then initiates the reaction in the section of the compact adjacent to it and fully propagates throughout the entire compact until completion. Initiation of the localized reaction is generally associated with the melting of the constituent with the lowest melting point, with instantaneous initiation of the reaction usually occurring close to that melting point [1]. This melting point can be high in some systems of interest, such as the titanium (Ti) and boron (B) system in equation 1:"

Jan 1, 2011

By Selvin Yesilay, Guray Kaya, Bekir Karasu, Asli Cakir

"In this investigation, the wastes of Eti Maden Kirka Boron Company of Turkiye were evaluated in the production of diopside and anorthite-based glass-ceramic glazes suitable for porcelain tiles fast and single-fired under industrial conditions. First of all, high wear resistant frits were produced with the use of concentrator and derivative borax wastes. Second of all, pre-engobed porcelain tile bodies were coated with the standard and newly produced frit-based glazes and industrial fast single-firing was employed. Final products were undergone to the certain standard tests to determine their Vickers hardness, wear resistance, thermal expansion coefficient values, gloss and coloring parameters. The micro-structures and phase formations of the fired glazes were also studied. Consequently, it was confirmed that the utilization of borax solid wastes in fast single-fired porcelain tile glass-ceramic glazes is possible. Introduction Porcelain tiles were introduced at the end of 1980s by Friandre, one of the leading Italian porcelain manufacturers. The American National Standard Specifications for Ceramic Tile defines porcelain tiles as: dense, smooth, impervious (with water absorption value less than 0.5 %) and stain resistant [1]. The excellent technical performances for ceramic tiles, such as mechanical, wear, frost and chemical resistance that make their use possible in indoor and outdoor building applications [2-3]. In the last decade, the growth rate of the global production of porcelain tiles increased more than those of other ceramic products; in fact, the technical properties of porcelain tile, coupled with even more improved aesthetic appearance, gave it a prominent role on the tile market [2]. Glass-ceramics are composed materials of one or more crystalline phases immersed in a residual glassy phase [4-5]. Glass-ceramic technology is based on controlled nucleation and crystallization of bulk glass [6]. The concepts of controlled crystallization of glass designate the separation of a crystalline phase from the parent glass in the form of tiny crystals. Their growth rate and final size are controlled by a suitable heat treatment [7]."

Jan 1, 2008

By Leijun Li, M. M. Mahapatra

"A three-dimensional finite element model with moving heat source was developed for pulsed-laser powder deposition (PLPD) process. Experiments were conducted to study the repair of superalloy components using the PLPD process. During the experiments, IN 625 powder was deposited on a superalloy substrate similar to IN 738. The process was modeled using three-dimensional finite element analysis. Element birth and death technique was used in the finite element model for simulating the deposition of powder layer on the substrate. A moving distributed heat source was used in the thermal model for realistic simulation of the process. Temperature dependent thermal material properties including enthalpy were used for the powder and the substrate in the transient thermal analyses. The fusion zones and peak temperature distributions of the deposits were predicted from the transient thermal analyses.IntroductionPoor weldability is a critical issue of superalloy repairing. The microstructural directionality of the superalloy components are disrupted when repaired by the fusion welding processes. Currently there is no widely accepted method to economically and reliably repair directionally solidified superalloys components. Pulsed laser powder deposition process (PLPD) is a promising repairing technique as the substrate is not severely affected by the heat source.In this study PLPD technology is used as the tool for superalloy repairing. In most of the land based turbine engines the directionally solidified nickel based superalloy similar to IN 738 [1] is used as the bucket material. The turbine engine blade tips are subjected to a combination of extreme operating conditions and corrosive environment. The tip of the nickel based turbine engine blades can be repaired using IN 625 material as suggested in the literature [1-2]. IN 625 is considered to be ductile and strong enough for the purpose of Ni based turbine engine blade tip repair[1-2]. During the present PLPD investigation, IN 625 powder was used as the deposit material on an experimental super alloy substrate similar to IN 738 superalloy used as the cast superalloy for the turbine engine blades."

Jan 1, 2012